PROBLEM SOLVING - PowerPoint PPT Presentation

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PROBLEM SOLVING

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PROBLEM SOLVING OLD METHOD Component Name : Gear Stay Component weight : 182Kgs Number of Castings per Mold : 1nos. Total Good Casting wt : 182Kgs – PowerPoint PPT presentation

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Title: PROBLEM SOLVING


1
PROBLEM SOLVING
OLD METHOD Component Name Gear Stay Component
weight 182Kgs Number of Castings per Mold
1nos. Total Good Casting wt 182Kgs Total
Pouring wt 310kgs Yield 58.5
PROBLEM DESCRIPTION Component getting rejected in
Ultrasonic testing for back wall echo loss.
2
Picture shows Metal Filling at various
intervals The colour scale shows the temperature
at each location
3
Picture shows Solidification at various
intervals The colour scale shows the of Liquid
metal available
Isolated region
4
Picture shows the possible Shrinkage area
This defect location exactly matches with
customer complaint
Shrinkage location
5
PROBLEM SOLVING
  • Corrective Action
  • Gating changed
  • Feeder size increased and number of feeders
    reduced 2

6
Picture shows Metal Filling at various
intervals The colour scale shows the temperature
at each location
7
Picture shows Solidification at various
intervals The colour scale shows the of Liquid
metal available
8
Picture shows the porosity locations There is no
defect inside the casting
9
  • Finding after implementation of this method
  • Hotspot moved to feeder and there is no defect
    noticed inside the casting.
  • Yield also increased by 10
  • 100 UT o.k and mold erosion problem eliminated.
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